Continuous high quality insulation and vulcanizing of high and extra high voltage cable. Thanks to accurate layer tolerances and precise control of material consumption, you also reduce your amount of scrap.

How to get more value?

Right capacity

How easily can you respond to market changes? Is your answer profitable enough for you? With us you can choose from three different capacity levels without compromising availability or quality of your production solution. Proactive services enhance your operations even further.

Lower production costs

Is material-efficiency important to you? Our technologies guarantee excellent centricity and high stability of your products. State-of-the-art extruders and crossheads save material and minimize scrap in your production. Versatile raw materials, that suit to your production in quality, quantity and price, are applicable on several technologies.

Sustainable products

How sustainable are your products? Purity and smoothness in layers are in the core of our solution development. With us, you can deliver more durable products that are easy to install and secure to use.

Our Way of Working

Production solution iteration

We simulate possible line configurations for different production speeds and spaces for you

Installation and production start

We supervise the installation at your premises to answer any questions which may arise. In each delivery, we do the line set-up to ensure that all our promises are fulfilled in the delivery.

Investment renewal

We help you to achieve the best production value throughout your investment lifecycle. There are several performance and upgrade services to explore new business opportunities.

EPL 51Extend
ShowHide

Lean and proven production solution for changing market needs. Good upgradability and versatile product range guarantee a technical fit for the future.

EPL 51Extend

Gain flexibility when producing quality high and extra high voltage XLPE cables

Are you looking for a flexible insulation and vulcanizing process which is easy to operate and performs reliably?

For your production of high and extra high voltage cables, our EPL 51 Extend offers you

High-quality results

Fast line speeds

Easy cable system installation and controlled material costs

What you get

Cable manufactured to meet specific requirements and international standards

Top-quality high and extra high voltage cable

High-performance high and extra high voltage cable production

Leading technology proven worldwide

Performance

Theoretical yearly capacity

200 km, 1000 mm2 Cu 220 kV

Typical line composition

FBO 30 Floor pay-off

FBO 30 Floor pay-off

KS160 Vertical cable clamp

SL 150 Dancer

MHE DB 2000LV/5+6/80m Accumulator

HSC 3500 V High Stability Capstan

EFD 50 Conductor Preheater

NXW 60-20D Water cooled extruder

NXW 175-24D Water cooled extruder

NXW 80-20D Water cooled extruder

NXW Cooling unit for extruder group

THX 70/150 Triple crosshead

IWT 300 Integrated Water Tempering unit

X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system

PDI Isolator

Gravity feeding

Semicon material drying and conveying

SB 200, Splice box

Curing tube CDCC, DN 250-7 zones

THS Tube heating system

N2P Nitrogen Pressure Control System

NCS Nitrogen Circulation System

Vertical Cooling Tube DN 200-48 m

PTP 3600L Pressurized Turn Pulley

Vertical Cooling Tube DN 200-36 m

OWCS Open Water Cooling System

ES 200 SS End seal

BCA 21 Caterpillar

SL 150 Dancer

BLMD 2000 Belt length measuring system

BCA 15 Caterpillar

FTU 30 Floor pay-off

FTU 30 Floor pay-off

Autocure 4.1 S7 Line Control

Optional component

By Product Separator

Show full listHide full list

Specifications

Voltage range

66 – 500 kV

Conductor cross section Cu mm2

240 –2500

Conductor cross section Al mm2

240 –2500

Conductor type

Round, solid, stranded, miiliken

Insulation layer thicknesses

Conductor screen (mm)

0.4 – 2.0 mm

Insulation (mm)

3.4 – 35

Insulation screen (mm)

0.4 – 2.0 mm

Max. cable weight (kg/m)

35

Max. Cable diameter (mm)

140

Height of the tower (m)

100

Constructive line speed (m/min)

10

Show full listHide full list

Value packages

Production Capacity

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Product Quality

Clean Run Value Package

While your compound suppliers provide clean XLPE insulation compounds, with our clean-run value package these compounds are kept clean. In fact, they are made even cleaner through the material conveying from the package to the extruder.

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Round Value Package Basic

The cooling circulation of nitrogen shrinks the outer surface of the insulation, thereby forcing the insulated core into its round shape. This process enables a catenary line with moderate rotation to produce cables with thick walls.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

Related services and solutions:

Service Level Agreement

With regular follow-up and predefined scheduled technical visits, we ensure the best operating reliability of your line by defining the status of your equipment and checking the adequacy of the preventive maintenance program.

24/7 Help Request

Spare Parts

We are committed to providing you with the best genuine spare parts and consumables. They are manufactured according to original Maillefer drawings, tested and checked with high quality criteria. We deliver them to you worldwide from our two main logistics centers in Switzerland and Finland, where we have stocked more than 30,000 different parts. We have also established remote emergency stock facilities in China, India, USA and Russia for our local customers, thus ensuring optimal delivery times. Only genuine Maillefer parts can guarantee the compatibility with your equipment and an optimum operation of your production line.

Preventive Maintenance

Training

The training courses are given at your site or at our Maillefer offices. The theory is covered in a classroom while the practical training takes place on the line. For each course training material is provided.

Royal road to demanding deliveries with the lowest total cost of ownership. High output solution to explore the market in the front row.

EPL 51Explore

Produce quality high and extra high voltage XLPE cables with high speed

Are you looking for a high-performing insulation and vulcanizing process which is easy to operate and performs reliably?

Our EPL 51 Explore line is designed for reliable, high-quality production of high and extra high voltage cables, and offers

First-rate production

High-speed production

Minimized material costs and easy installation

What you get

Cable manufactured to meet all relevant requirements and meets international standards

Top-quality high and extra high voltage cable

Exceptional high and extra high voltage cable production

Minimum tower height

Performance

Theoretical yearly capacity

250 km, 1000 mm2 Cu 220 kV

Typical line composition

FBO 30 Floor pay-off

FBO 30 Floor pay-off

KS160 Vertical cable clamp

SL 150 Dancer

MHE DB 2000LV/5+6/80m Accumulator

HSC 3500 V High Stability Capstan

EFD 50 Conductor Preheater

NXW 60-20D Water cooled extruder

NXW 200-24D Water cooled extruder

NXW 80-20D Water cooled extruder

NXW Cooling unit for extruder group

THX 70/165HV Triple crosshead

IWT 300 Integrated Water Tempering unit

X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system

PDI Isolator

Gravity feeding

Semicon material drying and conveying

SB 200 Splice box

Postheating equipment

Curing tube CDCC, DN 250-4 zones

THS Tube heating system

Vertical neutral tube DN250-5 m

N2P Nitrogen Pressure Control System

NCS Nitrogen Circulation System

Vertical Cooling Tube DN 260-60 m

PTP 3600U Pressurized Turn Pulley

Vertical Cooling Tube DN 250-42 m

OWCS Open Water Cooling System

ES 200 SS End seal

BCA 42 Caterpillar vertical

SL 150 Dancer

BLMD 2000 Belt length measuring system

BCA 15 Caterpillar

FTU 30 Floor pay-off

FTU 30 Floor pay-off

Autocure 4.1 S7 Line Control

Optional component

By Product Separator

Show full listHide full list

Specifications

Voltage range

66 – 500 kV

Conductor cross section Cu mm2

240 –3000

Conductor cross section Al mm2

240 –3000

Conductor type

Round, solid, stranded, miiliken

Insulation layer thicknesses

Conductor screen (mm)

0.4 – 2.0 mm

Insulation (mm)

3.4 – 35

Insulation screen (mm)

0.4 – 2.0 mm

Max. cable weight (kg/m)

40

Max. Cable diameter (mm)

150

Height of the tower (m)

100

Constructive line speed (m/min)

10

Show full listHide full list

Value packages

Production Capacity

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Product Quality

Clean Run Value Package

While your compound suppliers provide clean XLPE insulation compounds, with our clean-run value package these compounds are kept clean. In fact, they are made even cleaner through the material conveying from the package to the extruder.

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Round Value Package Basic

The cooling circulation of nitrogen shrinks the outer surface of the insulation, thereby forcing the insulated core into its round shape. This process enables a catenary line with moderate rotation to produce cables with thick walls.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

Preventive Maintenance

Spare Parts

We are committed to providing you with the best genuine spare parts and consumables. They are manufactured according to original Maillefer drawings, tested and checked with high quality criteria. We deliver them to you worldwide from our two main logistics centers in Switzerland and Finland, where we have stocked more than 30,000 different parts. We have also established remote emergency stock facilities in China, India, USA and Russia for our local customers, thus ensuring optimal delivery times. Only genuine Maillefer parts can guarantee the compatibility with your equipment and an optimum operation of your production line.

Service Level Agreement

With regular follow-up and predefined scheduled technical visits, we ensure the best operating reliability of your line by defining the status of your equipment and checking the adequacy of the preventive maintenance program.

Training

The training courses are given at your site or at our Maillefer offices. The theory is covered in a classroom while the practical training takes place on the line. For each course training material is provided.